Modular Light and Accessory Bar for Vehicles

ABSTRACT

A modular light and accessory bar for a vehicle includes a top rail having a length selected to span a width of the vehicle along the top of the windshield, a right end, and a left end. A right side pillar is configured to be attached to the top rail at the right end thereof and extend downwardly therefrom. A left side pillar is configured to be attached to the top rail at the left end thereof and extend downwardly therefrom. The top rail is formed with at least one T-slot that extends along the length of the top rail. At least one bracket is configured to support a lighting fixture or accessory and is attachable to the T-slot of the top rail at a desired location therealong. The T-slot is configured to permit the at least one bracket to be slid to a desired location along the top rail and secured at that location. The top rail may be curved forwardly relative to the vehicle.

REFERENCE TO RELATED APPLICATION

Priority is hereby claimed to the filing date of U.S. provisional patentapplication 62/458,280 filed on Feb. 13, 2017, the contents of which arehereby incorporated by reference.

TECHNICAL FIELD

This disclosure relates generally to automotive aftermarket products andmore particularly to aftermarket products and accessories for vehiclesdriven by their owners in rugged off-road environments, commonly knownas “off-road vehicles.”

BACKGROUND

Many owners and drivers of off-road vehicles such as Jeep® brandvehicles choose to enhance their stock vehicles with aftermarketaccessories. Such accessories might include, for example, light guards,snorkels, winches, wheels, suspensions, special ruggedized tires, andthe like. While some off-road accessories are decorative, most serve thepurpose of enhancing the resiliency and survivability of the vehicle, orenhancing the experience of a driver when the vehicle is driven on verydemanding and often punishing off-road terrain.

One accessory often added to an off-road vehicle is auxiliary lightingto make the path ahead more visible when off-roading after dark or inthe rain and fog. Auxiliary lighting can take many forms such as, forinstance, spotlights mounted on the windshield pillars, spotlightsmounted on the roof of the vehicle, lights mounted on the front fenderand/or its bars, spotlights mounted on a roll bar, and even lightsmounted on the hood. While these solutions for providing additionallight have proven useful, they nevertheless have certain problems andshortcomings inherent in their respective designs.

For example, the lights and mounting structures of prior art auxiliarylighting tend to be dedicated and permanent once mounted to the vehicle.It is difficult or impossible to exchange one type of lighting fixturefor another when desired or otherwise to reconfigure the lightingconfiguration. Further, the positioning of individual lights isgenerally fixed in prior art auxiliary lighting. There is littleprovision in the prior art for mounting accessories other than lightssuch as, for instance, mirrors or sports cameras. Finally, in many priorart auxiliary lighting systems, the wiring that supplies power tolighting fixtures is visible. This is problematic and undesirable formany off-road vehicle owners who prefer a neat clean appearance.

A need exists for an auxiliary lighting system for off-road vehiclesthat is modular, reconfigurable as needed by adding or removingindividual lighting fixtures or moving them to different locations, thatis neat and clean in appearance without visible wiring, and that isadapted for the convenient mounting of accessories other than lightswhen desired. It is to the provision of an auxiliary lighting andaccessory system for off-road vehicles that addresses these and otherneeds that the present invention is primarily directed.

SUMMARY

Briefly described, a modular light and accessory bar for a vehicleincludes two side pillars configured to be mounted to the vehicle to theright and the left of the front windshield. The side pillars extendupwardly from the body of the vehicle to a position just above the frontwindshield. A horizontally oriented top rail is secured at its ends tothe tops of the side pillars and extends over the top of the windshieldfrom side to side of the vehicle. Preferably, the top rail is slightlyforwardly curved. The top rail is provided with elongated T-slots thatextend from end to end to accept nuts used to secure mounting bracketsadjustably to the top rail.

A similar T-slot extends along the side pillars also for accepting nutsused to secure mounting brackets adjustably to the side pillars. Theside pillars also include an elongated wiring channel that is covered bya plastic cover. A wide array of different lighting fixtures can bemounted to the top rail and the side pillars in virtually any desiredconfiguration. In all cases, the wiring to such lights is routed throughthe wiring channel of the side pillars and hidden by the plastic covers.Mounting brackets of various configurations can be mounted to the toprail and side pillars for accepting a wide range of accessories otherthan lights. For example, side-view mirrors or GoPro® style sportscameras can be mounted as desired for a particular off-road outing.

These and other aspects, features, and advantages of the modular lightand accessory bar disclosed herein will be better appreciated uponreview of the detailed description set forth below taken in conjunctionwith the accompanying drawing figures, which are briefly described asfollows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a modular light and accessory bar thatembodies principles of the invention in one preferred embodiment, withthe light and accessory bar being shown mounted to an off-road vehicle.

FIG. 2 is a perspective view of the modular light and accessory bar ofFIG. 1 shown in isolation.

FIG. 3 is a perspective view of the modular light and accessory bar ofFIG. 2 with the individual lighting fixtures removed to reveal variousfeatures of the bar assembly.

FIG. 4 is a perspective partially exploded view of the upper rightcorner of the modular light and accessory bar showing one structure forsecuring the top rail of the assembly to the side pillars of theassembly.

FIG. 5 is a perspective view of one preferred embodiment of the top railof the assembly showing its curved shape and slotted features forattaching lights and accessories to the top rail.

FIG. 6 is a perspective view showing mounting brackets adjustablysecured to the top rail of the assembly for receiving and securinglighting fixtures or accessories to the top rail.

FIG. 7A is a perspective view showing a pivotable mounting bracketassembly, according to one embodiment. FIG. 7B is a perspective view ofa bracket of the assembly shown in FIG. 7A. FIG. 7C is a perspective,isolated view of the pivotable mounting bracket assembly of FIG. 7Asupporting one end of a fixture/accessory and secured to the top rail ofthe light and accessory bar assembly.

FIG. 8 is a perspective view of the left side pillar of the assemblyshowing its modular mounting features and wire routing channel, theright side rail being a mirror image thereof.

DETAILED DESCRIPTION

Reference will now be made in detail to the attached drawing figures,wherein like reference numerals refer to like parts throughout theseveral views. FIG. 1 depicts a vehicle 11, in this case a Jeep® brandvehicle, having a windshield 12. The windshield 12 has a top 13, a rightside 14, and a left side 16. Support pillars (not visible) extend alongthe extreme sides of the windshield and a header (also not visible)extends along the top of the windshield. An auxiliary light andaccessory bar assembly 17 is attached to the vehicle 11 and includes atop rail 18, a right side pillar 19, and a left side pillar 21. The toprail 18 extends across the vehicle at the top of the windshield and theright and left side pillars 19 and 21 extend along the support pillarsof the right and left sides 14 and 16 of the windshield as shown.

A plurality of spaced lighting fixtures 22 are supported on the top railand face forward to provide additional light ahead. Similarly, lightingfixtures 23 and 24 are attached to and spaced along the right and leftside pillars and, in this figure, also face forward to provideadditional light ahead. As discussed in more detail below, the lightingfixtures shown in FIG. 1 may easily be reconfigured or replaced by otherand different lighting fixtures or by other accessories such as mirrorsor sports cameras. In this way, the lighting and accessory bar of thepresent invention may be said to be “modular” in its uses.

FIG. 2 illustrates the auxiliary light and accessory bar 17 removed froma vehicle and shows certain aspects in more detail. The top rail 18 ofthe bar 17 is seen to be arched or curved from its left end to its rightend in a forward direction relative to a vehicle to which the bar 17 isattached. Lighting fixtures 22 are adjustably mounted to the top rail bymeans of mounting brackets 34 that are adjustably attached to the toprail with bolts 37 in a manner detailed below. Bolts 52 secure thelighting fixtures 22 to the adjustably attached mounting brackets 34 andallow the lighting fixtures 22 to be adjusted in orientation so thattheir light beams shine lower or higher as desired.

The left side pillar 21 is attached at its top end to the top rail 18 bymeans of a metal bracket 29. The metal bracket 29 is mostly covered by aplastic bracket cover 31, which improves the aesthetics of the assemblywhen mounted to a vehicle. A plurality of lighting fixtures 24 ismounted at spaced intervals along the left side pillar with thepositions of the lighting fixtures being adjustable along the sidepillar. More specifically, mounting brackets 36 (FIG. 3) are adjustablyattachable to the left side pillar by means of bolts 38 and the lightingfixtures are mounted to the mounting brackets 36 by means of bolts 40. Awiring port cover 27 extends inwardly from the bottom end of left sidepillar 21 for purposes described in more detail below.

The right side pillar 19 is a mirror image of the left side pillar andthus need not be described in great detail. The right side pillar 19 isattached at its top end with a bracket (not visible) to the right end ofthe top rail 18 and extends downwardly therefrom. The bracket is coveredwith a bracket cover 33 to hide the bracket and obtain a more pleasingfinished appearance. A plurality of mounting brackets 36 is adjustablyattached to the right side pillar and each supports a lighting fixture23 attached with a bolt 40. As with the left side pillar 21, each of themounting brackets 36 can be secured to the right side pillar at anydesired location therealong to secure lighting fixtures or otherauxiliary items at desired positions.

FIG. 3 shows a preferred embodiment of the auxiliary lighting andaccessory bar 17 without lighting fixtures or other accessoriesattached. Mounting brackets 34 are seen here to be adjustably secured tothe top rail 18 with bolts 37. Mounting brackets 36 are adjustablyattached to the right and left side pillars with bolts 38. The rightside wiring port cover 26 extends inwardly from the right side pillar 19and left side wiring port cover 27 extends inwardly from the left sidepillar 21. A right side wiring channel cover 60 covers a wiring channelformed along the right side pillar (detailed below) and a left sidewiring channel cover 61 covers a wiring channel formed along the leftside pillar.

FIG. 4 shows the attachment of the left side pillar 21 to the top rail.More specifically, a metal bracket 29 is configured to attach at one endto the top rail by means of bolts, screws, clips, or other appropriatefasteners. The other end of the metal bracket 29 is attachable to thetop end of the left side pillar by means of bolts, screws, clips, orother appropriate fasteners. In this way, the left side pillar issecurely fixed to the top rail (as is the right side pillar). The leftbracket cover, which may be fabricated from molded plastic, isconfigured to slide over the metal bracket 29 covering the bracket andpartially covering the ends of the top rail and the left side pillar.This hides the metal bracket 29 and presents a more pleasing appearancewhen the assembly is mounted to a vehicle. It will be understood thatthe right side pillar, although mirrored, is attached to the right endof the top rail in the same way as the left side pillar.

FIG. 5 depicts the top rail 18 as seen from the right end portionthereof. The top rail preferably is fabricated as an aluminum extrusion,but may be made of other metals or plastics and through processes otherthan extrusion if desired. The top rail has a back 42 from which anupper shield 41 extends forwardly. The top rail is profiled to define atop T-channel 43, a middle T-channel 44, and a bottom T-channel 46. Thetop T-channel 43 includes a longitudinally extending nut slot definedbetween opposing structures 73 and 74. Similarly, the middle T-channel44 includes a longitudinally extending nut slot defined between opposingstructures 76 and 77 and the bottom T-channel 46 includes alongitudinally extending nut slot defined between opposing structures 78and 79.

Each of the nut slots is sized to receive threaded nuts and to allow thethreaded nuts to be slid along the length of the nut slot whilerestraining the nuts from rotating within the nut slot. These nuts areconfigured to receive attachment bolts used to hold mounting brackets 34to the top rail. In practice, bolts are extended through a mountingbracket, through the open end of a T-channel, and threaded into a nutlocated within a nut slot of the top rail. The mounting bracket, bolts,and nuts can then be slid to a desired location along the top rail withthe nuts sliding in their nut slots, whereupon the bolt can be tightenedto secure the mounting bracket in place at that location. The forwardcurvature of the top rail 18 is clearly visible in FIG. 5 and screwbosses 48 and 49 may be extruded with the top rail to receive screws ofthe metal bracket 29 used to attach a side pillar to the top rail 18.

FIG. 6 illustrates better the fixing of mounting brackets 34 to the toprail 18 as described. Each mounting bracket 34 has a base 35 throughwhich a pair of mounting holes (not visible) extends. The mounting holesare positioned to align, in this case, with the upper T-channel 43 andthe lower T-channel 46. Nuts 51 are slidably but non-rotatablypositioned in the nut slots of the upper and lower T-channels 43 and 46.Bolts 37 extend through the openings of respective T-channels and eachbolt is threaded into a corresponding nut in the nut slot of theunderlying T-channel. While simple mounting brackets 34 are shown inFIG. 6, it will be understood that mounting brackets of many differentconfigurations may be attached to the top rail in the manner describedfor receiving different lighting fixtures or accessories to be mountedto the top rail.

It will be seen that with the nut loosely threaded in the mannerdescribed above, the entire assembly including mounting bracket 34, itsassociated bolts 37, and its associated nuts 51 can be slid along thetop rail to any desired location. Tightening of the bolt then securesthe mounting bracket to the top rail at that location. Lighting fixturemounting bolts 52 are shown in FIG. 6 for threading into the ends of alighting fixture or other accessory located between two mountingbrackets thereby securing the lighting fixture or other accessory to thetop rail (See FIG. 1).

To assist with aligned mounting of, for example, lighting fixtures 22 tothe top rail when, for example, the top rail is of an embodiment that isforwardly curved, a pivotable bracket assembly 70 may be employed. Onesuch pivotable bracket assembly 70 is depicted in FIGS. 7A-7C. Withreference to FIGS. 7A-7C, the pivotable bracket assembly 70 includes amounting bracket 34′ formed with a curved bottom segment 71 and anextending fixture-support 72, giving the bracket 34′ a type of “J”shape. The bracket assembly 70 further includes independent base plates35′ that fit into the groove 73 of the bottom segment 71 in such amanner that they may move relative to the bracket 34′. Though it is notrequired, it is preferred that the base plates 35′ have a semicircularprofile, as depicted in FIG. 7A, such that they match the profile of thegroove 73 and pivot within the groove relative to the bottom segment 71.As seen best in FIG. 7 B, the bracket 34′ includes elongated boltpassages (or mounting holes) 55 through which bolts 37 may pass when thebracket assembly 70 is being mounted to the top rail 18, for example atT-channels 43, 46. Thus, with reference to FIG. 7 A (and in part to FIG.6) each pivotable mounting bracket assembly 70 is positioned at the toprail 18 with its elongated bolt passages 55 aligned, in this case, withthe T-channels 43, 46. Nuts 51 are slidably but non-rotatably positionedin the nut slots of the upper and lower T-channels 43 and 46. Bolts 37extend through the base plates 35′, through the bolt passages of thebracket 34′ and into the nuts 51, and each bolt is threaded into thecorresponding nut of the underlying T-channel.

With the nuts loosely threaded in the manner described above, the entirepivotable bracket assembly 70 can be slid along the top rail 18 to anydesired location. Additionally, the pivotable mounting bracket 34′ maybe pivoted on its curved bottom segment 71 against the top rail, suchthat the bracket 34′ may be adjusted in its angle relative to the rail18. The elongated bolt passages 55 and the independent plates 35′ allowperpendicular entry of the bolts 37 into the channels 43, 46 and intothe nuts 51, while at the same time allowing pivoting of the bracket 34′relative to the bolts and, thus, pivoting of the bracket on its curvedbottom segment 71 relative to the top rail 18. For example, theextending fixture-supports 72 of adjacent bracket assemblies 70 may beadjusted by this pivoting to extend outwardly at various angles from thetop rail 18 in order that the fixture attached to the supports, forexample a light fixture 22, may be forward facing regardless of wherethe fixture is mounted along the curve of the top rail. Tightening ofthe bolts then secures the otherwise pivotable mounting bracket assembly70 to the top rail at that location and in the selectedangled-Orientation.

FIG. 8 is an enlarged perspective of the left side pillar illustratingbetter some of its features. The left side pillar 21 preferably is madeof extruded aluminum, but may be made from another metal or material orwith a process other than extrusion within the scope of the invention.The left side pillar has a body 56 that is arched to extend neatlyaround the left support pillar of the windshield. Mounting holes 58 aresized to receive screws or other fasteners used to attach the left sidepillar 21 to the support pillar. Other mounting holes may be formed atother locations on the pillar to ensure that the pillar is securelyattached to its support pillar.

The left side pillar 21 is profiled to define a longitudinally extendingT-channel 57 extending from the top end of the left side pillar 21 tothe bottom end of the left side pillar. The T-channel defines alongitudinally extending nut slot that is sized to receive nuts 50 andallow them to slide along the T-channel while preventing the nuts fromrotating with the T-channel. One or more mounting brackets 36 can beloosely mounted to the left side pillar 21 by extending a bolt 38through a mounting hole in the mounting bracket, threading it looselyinto a nut, and sliding the mounting bracket, bolt, and nut along theT-channel to a desired location. The bolt 38 can then be tightened tosecure the mounting bracket 36 in place at that location.

The left side pillar 21 is further profiled to define a wiring channel59 that extends along the length of the pillar from the top of thepillar to the bottom of the pillar. The wiring channel is configured toreceive a wiring channel cover 61 that covers the open top of the wiringchannel. More specifically, an arrow-shaped tang 62 extending along oneside of the wiring channel is sized and shaped to be received in asimilarly shaped channel formed along one side of the wiring channelcover 61. A slot 64 is formed along the opposite side of the wiringchannel and is configured to capture an out-turned lip 63 along theopposite side of the wiring channel cover 61. With such an embodiment,the wiring channel cover can be slid easily onto and off of the leftside pillar as indicated by arrows 66.

When routing wiring that supplies power or signal to a lighting fixtureor accessory mounted on the left side pillar 21, the wires are routedfrom their source within the vehicle and through the body of the vehicleat a location covered by the left wiring port cover 27. The wiring canthen be routed through the wiring channel 59. When one or more wiresneeds to exit the channel to connect to a lighting fixture or otheraccessory, a small hole or slot can be formed in the plastic wiringchannel cover 61 at the appropriate location. The wires are thenthreaded through the hole or slot and attached to the lighting fixtureor accessory. Wiring associated with lighting fixtures or accessoriesmounted to the top rail can be routed through the wiring channel 59 ofone of the side pillars and through a T-channel of the top rail. In thisway, substantially all of the wiring associated with lighting andaccessories attached to the light bar assembly is hidden and a neatclean appearance is presented.

The invention has been described herein in terms of preferredembodiments and methodologies that exemplify the invention and that areconsidered by the inventors to represent the best modes of carrying outthe invention. A variety of additions, deletions, and modifications,both subtle and gross, might well be made to the illustrated embodimentswithout departing from the spirit and scope of the invention, which isdelineated only by the claims.

What is claimed is:
 1. A modular light and accessory bar for a vehiclecomprising: a top rail having a length selected to span substantially awidth of the vehicle at a top of the vehicle, a right end, and a leftend; a right side pillar configured to be attached to the top rail atthe right end thereof and extend downwardly therefrom; a left sidepillar configured to be attached to the top rail at the left end thereofand extend downwardly therefrom; the top rail being formed with at leastone attachment feature extending therealong; a least one bracketconfigured to support a lighting fixture or accessory; the at least onebracket being attachable to the attachment feature of the top rail; theattachment feature being configured to permit the at least one bracketto be attached at any desired location along the top rail.
 2. A modularlight and accessory bar for a vehicle as claimed in claim 1 wherein theattachment feature of the top rail comprises at least one slot extendingalong the length of the top rail.
 3. A modular light and accessory barfor a vehicle as claimed in claim 2 wherein the at least one slotcomprises at least two slots.
 4. A modular light and accessory bar for avehicle as claimed in claim 2 wherein the at least one slot comprises atleast one T-slot.
 5. A modular light and accessory bar for a vehicle asclaimed in claim 4 further comprising opposing features in the at leastone T-slot that define a nut slot extending along the length of the toprail.
 6. A modular light and accessory bar for a vehicle as claimed inclaim 1 further comprising a first bracket securing the first sidepillar to the first end of the top rail.
 7. A modular light andaccessory bar for a vehicle as claimed in claim 6 further comprising asecond bracket securing the second side pillar to the second end of thetop rail.
 8. A modular light and accessory bar for a vehicle as claimedin claim 1 further comprising a right attachment feature extending alongthe right side pillar and a left attachment feature extending along theleft side pillar, the right and left attachment features beingconfigured to receive and support at least one bracket for securing alighting fixture or accessory at a desired location along the right andleft side pillars.
 9. A modular light and accessory bar for a vehicle asclaimed in claim 8 wherein the attachment feature of the left sidepillar and the attachment feature of the right side pillar comprise aslot extending along the respective side pillar.
 10. A modular light andaccessory bar for a vehicle as claimed in claim 9 wherein the slotcomprises a T-slot.
 11. A modular light and accessory bar for a vehicleas claimed in claim 8 further comprising a wiring channel extendingalong he right side pillar and a wiring channel extending along the leftside pillar, the wiring channels being configured to contain wiringrelated to lights or accessories mounted to the side pillars and the toprail.
 12. A modular light and accessory bar for a vehicle as claimed inclaim 11 further comprising a cover over the wiring channels.
 13. Amodular light and accessory bar for a vehicle as claimed in claim 12wherein each of the covers is removably attached to the correspondingside pillar.
 14. A modular light and accessory bar for a vehicle asclaimed in claim 13 wherein each of the covers is slidably removablyattached to the corresponding side pillar.
 15. A modular light andaccessory bar for a vehicle as claimed in claim 1 wherein the top railis curved forwardly relative to a vehicle to which the modular light andaccessory bar is attached.
 16. A modular light and accessory bar for avehicle as claimed in claim 15 wherein the at least one bracketcomprises a curved bottom segment and a fixture-support extending fromthe curved bottom segment.
 17. A modular light and accessory bar for avehicle as claimed in claim 16, wherein, when the at least one bracketis attached to the attachment feature, the curved bottom segment isadjacent the attachment feature and the at least one bracket ispivotable on the bottom segment relative to the attachment feature. 18.A modular light and accessory bar for a vehicle as claimed in claim 1wherein the at least one bracket comprises a curved bottom segment and afixture-support extending from the curved bottom segment.
 19. A modularlight and accessory bar for attachment to a vehicle having a windshieldwith a top edge, a right side edge, and a left side edge, the modularlight and accessory bar comprising a right side pillar configured to beattached to the vehicle extending along the right side edge of thewindshield, a left side pillar configured to be attached to the vehicleextending along the left side edge of the windshield, and a top railconfigured to extend along the top edge of the windshield between a topend of the right side pillar and a top end of the left side pillar, atleast one slot extending along the length of the right side pillar andbeing configured to receive at least one fastener element and to allowthe fastener element to slide along the length of the at least one slot,at least one slot extending along the length of the left side pillar andbeing configured to receive at least one fastener element, at least oneslot extending along the top rail and being configured to receive afastener element and to allow the fastener element to slide along thelength of the at least one slot, at least one mounting bracketattachable to the at least one fastener element of the right side pillarand movable therewith along the length of the slot thereof, at least onemounting bracket attachable to the at least one fastener element of theleft side pillar and movable therewith along the length of the slotthereof, and at least one mounting bracket attachable to the at leastone fastener element of the top rail and movable therewith along thelength of the slot thereof, the mounting brackets being configured toreceive and secure lighting fixtures or accessories to the left sidepillar, the right side pillar, and the top rail.
 20. A modular light andaccessory bar as claimed in claim 19 further comprising a right sidewiring channel extending along the right side pillar and a left sidewiring channel extending along the left side pillar, the right and leftside wiring channels being configured to contain wiring associated withlighting fixtures or accessories attached to the modular light andaccessory bar.
 21. A modular light and accessory bar as claimed in claim20 further comprising a wiring channel cover removably attached to eachof the right side pillar and the left side pillar, the wiring channelcovers covering their respective channels and wiring disposed therein.22. A modular light and accessory bar as claimed in claim 19 wherein thetop rail is curved forwardly relative to a vehicle to which the modularlight and accessory bar is attached.
 23. A modular light and accessorybar for a vehicle as claimed in claim 22 wherein the at least onebracket comprises a curved bottom segment and a fixture-supportextending from the curved bottom segment.
 24. A modular light andaccessory bar for a vehicle as claimed in claim 23, wherein, when the atleast one bracket is attached to the attachment feature, the curvedbottom segment is adjacent the attachment feature and the at least onebracket is pivotable on the bottom segment relative to the attachmentfeature.
 25. A modular light and accessory bar for a vehicle as claimedin claim 19 wherein the at least one bracket comprises a curved bottomsegment and a fixture-support extending from the curved bottom segment.